Oil-free Air Division

1.

Oil-free Air Division
Teletraining
July 2005
1

2. ZH-Series

The unique packaging concept
Performances of a
State-of-the-art
Process compressor
Convenience of the
Integrated
Packaged Unit
Oil-free Air Division
Teletraining
July 2005
2

3. ZH-Series

Unique Package Concept
Oil-free Air Division
Teletraining
July 2005
3

4. COOPER

5. ZH and TA product range

Oil-free Air Division
Teletraining
July 2005
5

6. TA2000

2 and 3 stages
2.5 – 10.5 bar
130 – 300 kW
45 – 150 Psig
150- 350 Hp
TAC2000:
– Air-cooled unit
– Ambient temp. up to
40°C (105 F)
Oil-free Air Division
Teletraining
July 2005
6

7. TA3000

2 – 3 stages
2.5 – 10.5 bar
1500 – 2500 kW
45 – 150 Psig
400-800 Hp
Oil-free Air Division
Teletraining
July 2005
7

8. TA6000

2 and 3 stages
2.5 – 10.5 bar
685 – 1290 kW
45 – 150 Psig
800-1500 Hp
Oil-free Air Division
Teletraining
July 2005
8

9. TA11000

2 – 3 and 4 stages
2.5 – 16 bar
900 – 1900 kW
35 – 232 Psig
1250 – 2500 Hp
Oil-free Air Division
Teletraining
July 2005
9

10. Convenience of a packaged unit

ZH
Competition
Complete packaged unit
Conventional packaged design
Clear capital cost
No costly additions
Easy installation
Oil-free Air Division
Teletraining
July 2005
Uncomplete machine
Loose delivered items
Costly installation
10

11. Lowest Noise level in industry

ZH
Competition
Optional noise hood
No silencing hood available
– 68 ... 74 dBA
Oil-free Air Division
– Typically 82+ dBA
Teletraining
July 2005
11

12. Convenience of packaged unit

ZH
Competition
Complete packaged unit
Conventional packaged unit
Levelled floor
No anchoring system
Heavy fundations
Anchoring systems
Oil-free Air Division
Teletraining
July 2005
12

13. Clear capital cost

The complete package includes
Air intake filter and silencer
Inlet guide vanes
Aftercooler
Check valve
Cooling water manifold
Drain traps on all coolers
Compensators on air and
water inlet and outlets
IP23 motor
Control and safety system
integrated modulating blow-off valve
and blow-off silencer
Oil-free Air Division
Teletraining
July 2005
13

14. Conventional package

Air filter
and strainer $4,500
Blow-off
valve &
silencer
$8,000
Expansion
joints $500
Oil heater,
mixing valve
$3,000
Additional air &
drain piping
$6,000
Cooling
water
manifold
$2,000
Oil-free Air Division
Instrument air
piping $2,000
Sidemounted
aftercooler
$22,000
Teletraining
July 2005
Check
valve
$2,500
Expansion
joints $2,000
$50’000
adders
14

15. Convenience of packaged unit

ZH
Competition
Complete packaged unit
Conventional packaged unit
AIR INLET SYSTEM
MOUNTED IN PACKAGE
LOOSE DELIVERED
MOUNTED BY CUSTOMER
ON-SITE
–
–
–
–
Oil-free Air Division
Teletraining
July 2005
Inlet filter system
Air intake piping
Air intake screen
Air in/out compensators
15

16. Convenience of packaged unit

ZH
COMPETITION
INTEGRATED & MOUNTED
LOOSE DELIVERED
COMPONENTS
Low noise Integrated Blow-off
silencer
Piping
No need for external air
Modulating blow-off valve
Integrated after cooler
Oil-free Air Division
Relying on external instrument
air
Teletraining
July 2005
16

17. Auto-Dual & Constant Pressure Control Configurations of TA’s

Convenience of packaged unit
ZH
Competition
INTEGRATED & MOUNTED
Cooling water manifold
Water in/outlet compensator
Condensate drain system
LOOSE DELIVERED
MOUNTED ON-SITE
Oil-free Air Division
Teletraining
July 2005
18

18. Convenience of packaged unit

Lasting compressor performance
ZH
Competition
Clearances between
impeller and inducer not
affected over time due to
coating
Deterioration of performance
with larger clearances due to
corrosion
Cooler performance not
affected due to corrosionresistant coating
Oil-free Air Division
Lower heat removal capacity
of coolers due to obstructed
cooler tubes
Teletraining
July 2005
19

19. Lasting compressor performance

Reliability first with Stainless Steel
ZH
Competition
STAINLESS STEEL
Superior corrosion
resistance
Welded construction
COPPER + ALUMINIUM
Carbon steel end plates
Cu + Al > galvanic corrosion
Prone to water leaks
Price adder for SS: $34’000 !
U-bend >> no rodding
Clogging of small tube
diameters
Water-in-tubes, straight
Rodding with bundles inplace
Oil-free Air Division
Teletraining
July 2005
20

20. Reliability first with Stainless Steel

Reliability first with quality gears
ZH
COMPLETE GEAR/PINIONS
AGMA Q13
Aircraft quality gearing
Competition
AGMA Q12
Replacement of bull gear
and pinions in case one fails
>> very high cost if it happens
>> complicated maintenance
Increase of reliability
Lower mechanical forces
Lower noise levels
Reduced gearbox losses
Oil-free Air Division
Teletraining
July 2005
21

21. Reliability first with quality gears

Designed for easy maintenance
ZH
TA2000-3000-6000
MICRO SPLIN
Disassembly of impeller onsite
Micro-splin attachment
avoids fretting corrosion
SHRINK FIT (HEAT)
No inspection of bearings
on-site
Complete rotor assembly to
be returned to factory
Oil-free Air Division
Teletraining
July 2005
22

22. Designed for easy maintenance

No comprises on reliability
ZH
TA2000-3000-6000
TILTING PAD
HORIZONTALLY-SPLIT
Maintenance and inspection
FIXED GEOMETRY BEARING
(Hydro-squeeze)
Thrust collar (rider rings)
Thrust bearings for axial forces
Highest stability and reliability
Inspection & replacement on-site
Oil-free Air Division
Teletraining
July 2005
24

23. No compromises on reliability

No comprises on reliability ??
ZH
TA 11000 & MSG
Why not on the smaller frames
if they know that the tilting pad
bearings give the best result?
Oil-free Air Division
Teletraining
July 2005
25

24. No comprises on reliability

High speed and Low speed bearings
ZH
TA
AXIAL FORCES
in TWO DIRECTIONS
THRUST COLLARS
ROLLER BEARINGS
Reliability and safe design
Sleeve bearings on low
speed shaft >> extended
lifetime
Sensitive to varying
load/unload cycles
Risk of metal fretting
Large clearance between
shroud and impeller
>> higher SER
Oil-free Air Division
Teletraining
July 2005
26

25. No comprises on reliability ??

Lasting compressor performance
ZH
TA2000/3000/6000
CARBON RING AIR SEAL
LABYRINTH OIL SEAL
LABYRINTH SEAL
Patented combination
No external air
Minimal losses
Oil-free Air Division
Aluminium labyrinth teeth
Vibrations will damage seal
High leakage rate
Prone to wear
Teletraining
July 2005
27

26. High speed and Low speed bearings

Designed for easy maintenance
ZH
TA2000-3000-6000
MOTOR DRIVEN DEMISTER
EJECTOR TYPE VACUUM
No external air
No fumes leaking to
atmosphere
visible oil spill to atmosphere
25 m³/h (15 cfm) instrument
air permanent consumption
Oil-free Air Division
Teletraining
July 2005
28

27. Lasting compressor performance

INGERSOLL-RAND

28. Designed for easy maintenance

Ingersoll Rand - Centac Models
CV2/2CC model
30-100 m³/mn or 1060-3530 icfm
3.5 to 10 bar(g) or 50 to 150 psig
C950
90-170 m³/mn or 3200-6000 icfm
3.4 to 10 bar(g) or 50 to 150 psig
3CII model
170-250 m³/mn or 6000-9000 icfm
3.0 to 17 bar(g) or 40 to 150 psig
Oil-free Air Division
Teletraining
July 2005
30

29. INGERSOLL-RAND

Product range
ZH RANGE
Oil-free Air Division
Teletraining
July 2005
31

30. Ingersoll Rand - Centac Models

Product range
INGERSOLL-RAND
3CII
3CII
2CII
2CII
C950
C950
2CC
2CC
EPF
EPF
CV2
CV2
1ACII
1ACII
C350
C350
C250
C250
CV1B
CV1B
CV1A
CV1A
CV1
CV1
#N/A#N/A
ZH9-15000-3S
ZH9-15000-3S
ZH6-10000-3S
ZH6-10000-3S
ZH4-7000-3S
ZH4-7000-3S
2,500
5,000
7,500
10,000
12,500
15,000
17,500
[m³/hr]
Oil-free Air Division
Teletraining
July 2005
32
20,000

31. Product range

Convenience of a packaged unit
ZH
I-R CENTAC
Complete packaged unit
Conventional packaged design
Clear capital cost
No costly additions
Easy installation
Oil-free Air Division
Teletraining
July 2005
Uncomplete machine
Loose delivered items
Costly installation
34

32. Product range

Lowest Noise level in industry
ZH
Optional noise hood
Competition
No silencing hood available
– 68 ... 74 dBA
Oil-free Air Division
– Typically 82+ dBA
Teletraining
July 2005
35

33. CENTAC Product naming

Convenience of packaged unit
ZH
Competition
Complete packaged unit
Conventional packaged unit
Levelled floor
No anchoring system
Heavy fundations
Anchoring systems
Oil-free Air Division
Teletraining
July 2005
36

34. Convenience of a packaged unit

Centac CV2
Standard Scope of Supply Includes:
• Built in lubrication and cooling systems
• Flanged mounted motor
• Control system
• Single point flanged connections for air and water
• Single point power connection for low voltage motors
• Inlet air filter & by-Pass silencer shipped loose, to be mounted separately
Options:
• Silencing canopy 75 dB(A), adder $9,000
• Inlet guide vanes, adder $8,000
• Cu-Ni cooler bundle tubes, adder $4,000
Oil-free Air Division
Teletraining
July 2005
38

35. Lowest Noise level in industry

Centac C950
Standard Scope of Supply Includes:
• Built in lubrication and cooling systems, including aftercooler
• Foot mounted motor
• Control system
• Inlet air filter & by-Pass silencer shipped loose, to be mounted separately
Options:
• Silencing canopy, adder $12,000
• Inlet guide vanes, adder $10,000
• Cooling water manifold, adder $6,000
• Copper-nickel cooler bundle tubes, adder $5,000
Oil-free Air Division
Teletraining
July 2005
39

36. Convenience of packaged unit

Centac 3CII
Standard Scope of Supply Includes:
• Built in lubrication and cooling systems, including aftercooler
• Foot mounted motor
• Control system
• Inlet air filter & by-Pass silencer shipped loose, to be mounted separately
Options:
Silencing canopy, adder $15,000
Inlet guide vanes, adder $16,000
Cooling water manifold, adder $8,000
Copper-nickel cooler bundle tubes, adder $7,000
Oil-free Air Division
Teletraining
July 2005
40

37. Clear capital cost

Gearbox configuration
ZH
I-R CENTAC
HORIZONTALLY-split gearbox
Integration of gearbox and
donut coolers
2
1
2
3
3
1
PROCESS REQUIREMENT
More high-speed rotation
components
– Reliable
– Easy inspection &
maintenance
Oil-free Air Division
Teletraining
July 2005
44

38. Centac CV2

High speed and Low speed bearings
ZH
I-R CENTAC
AXIAL FORCES
in TWO DIRECTIONS
THRUST COLLAR
in ONE direction
???
Reliability and safe design
Sleeve bearings on low
speed shaft >> extended
lifetime
Oil-free Air Division
Sensitive to varying
load/unload cycles >> only
CPC
Risk of metal fretting
Teletraining
July 2005
45

39. Centac C950

Designed for easy maintenance
ZH
I-R CENTAC
HORIZONTALLY-split
Gearbox and bearings
VERTICALLY-split gearbox
Inspection of internal parts:
2 ½ hours
PROCESS REQUIREMENT
Inspection bearings: 30 hours !
High maintenance cost
Only AGMA Q11/Q12
Oil-free Air Division
Extremely high service cost
Teletraining
July 2005
46

40. Centac 3CII

Reliability first with quality gears
ZH
Competition
COMPLETE GEAR/PINIONS
AGMA Q13
Highest quality in industry
AGMA Q12
Replacement item
Increase of reliability
Lower mechanical forces
Lower noise levels
Reduced gearbox losses
Oil-free Air Division
Teletraining
July 2005
47

41. Convenience of packaged unit

Designed for easy maintenance
ZH
I-R CENTAC
MICRO SPLIN
Disassembly of impeller onsite
Micro-splin attachment
avoids fretting corrosion
POLYGONE SHRINK FIT +
BOLT
Difficult to (dis)assemble
High risk of fretting
Oil-free Air Division
Teletraining
July 2005
48

42. Convenience of packaged unit

Designed for easy maintenance
ZH
I-R CENTAC
TILTING PAD
HORIZONTALLY-SPLIT
Maintenance and inspection
FIXED GEOMETRY
Less stable
Low frictional losses
Low manufacturing cost
Sensitive to oil quality
Very small tolerances
to maintain stability during
start-up
Complete compressor
disassembly required for
inspection or replacement
Thrust bearings for axial
forces
Highest stability and reliability
Inspection & replacement on-site
Oil-free Air Division
Teletraining
July 2005
49

43. Convenience of packaged unit

No dependence on external air
ZH
I-R CENTAC
CARBON RING AIR SEAL
LABYRINTH OIL SEAL
Patented combination
Double protection
No external air
Minimal losses
Oil-free Air Division
Seal air required
to ensure oil-free air
Carbon rings
for oil and air seal
Teletraining
July 2005
50

44. Gearbox configuration

Reliability first with Stainless Steel
ZH
I-R CENTAC
STAINLESS STEEL
Superior corrosion
resistance
Welded construction
COPPER
Both for tubes & fins
Fins: copper with solder
coating
Cu + Al > galvanic corrosion
Water-in-tubes, straight
Rodding with bundles inplace
Oil-free Air Division
– Prone to water leaks
Air-in-tubes
Chemical cleaning, no
rodding
Teletraining
July 2005
51

45. High speed and Low speed bearings

Designed for easy maintenance
ZH
I-R CENTAC
Cooler performance not
affected due to corrosionresistant coating
COPPER
Coolers are consumable parts
Chemical cleaning
Corrosed internals
Clearances between
impeller and inducer not
affected over time due to
coating
Oil-free Air Division
Stainless steel extremely
expensive option
Copper Nickel optionally
Teletraining
July 2005
52

46. Designed for easy maintenance

ZH
I-R CENTAC
HORIZONTALLY-split gearbox
OIL TANK OIL QUANTITIES
– Only 250 l
– Operating life time over 2
years with sampling after
the second year
Increased uptime, reduced
downtime
Oil-free Air Division
–
–
–
–
Oil containging frame
400 l oil
Expensive oil
Operating life time 2 years
Designed for service revenues
Teletraining
July 2005
53

47. Reliability first with quality gears

Designed for easy maintenance
ZH
I-R CENTAC
MOTOR DRIVEN DEMISTER
CARTRIDGE
No external air
No fumes leaking to
atmosphere
visible oil spill to atmosphere
Oil-free Air Division
Teletraining
July 2005
54

48. Designed for easy maintenance

Efficient operation with IGV
ZH
I-R CENTAC
INLET GUIDE VANES (IGV)
save 9% of energy
Redirecting the flow path by
pre whirling
Increased turndown
Efficient control in case
closely positioned to the first
impeller
THROTTLE VALVE
Higher energy consumption
and smaller turndown
– throttling the flow increase
pressure drops
>> money down the drain
IGVs on Centac not effective
due to location
Oil-free Air Division
Teletraining
July 2005
55

49. Designed for easy maintenance

No dependence on external air
ZH
I-R CENTAC
ELECTRICAL ACTUATORS
PNEUMATIC ACTUATORS
No dependence on external
air supply
On IGV and Blow-off valve
Machine trips due to failure
in supply of instrument air
Oil-free Air Division
Teletraining
July 2005
58

50. No dependence on external air

ZH SERIES
External Buffer Air
Inlet Filter/Silencer
UNIQUE
COMPLETE
SOLUTION
Control Valve
Outlet Compensator
Additional Piping
Blow-off Silencer
Anchor Bolts
Special Foundation
Check Valve
Aftercooler
Blow-off Valve
CREATING CUSTOMER’S ADDED VALUE
Cooling Water Manifold
Oil-free Air Division
Teletraining
July 2005
Inlet Compensator
59

51. Reliability first with Stainless Steel

Thank You